Wall panel with assymetrically rabbeted edges

ABSTRACT

In at least one embodiment it is contemplated that the present invention provides a wall panel longitudinally extending between a first end and a second end and having a first inner surface, a second outer surface, a first longitudinal edge and a second longitudinal edge, the first longitudinal edge having a first longitudinally extending rabbet that abuts the first planar surface and having a longitudinally extending perpendicular shoulder wall adjoining a longitudinally extending outer planar surface parallel to the first planar surface, a second longitudinally extending rabbit that abuts the second planar surface and having a longitudinally extending perpendicular second shoulder wall adjoining a longitudinally extending sloped portion, the first longitudinally extending rabbet being wider than the second longitudinally extending rabbet, the second longitudinal edge having a longitudinally extending first flange abutting the first planar surface and having a first flange edge, a longitudinally extending second flange abutting the second planar surface and having a second flange edge, the first flange being wider than the second flange, the first flange and the second flange defining a longitudinally extending groove therebetween, the groove having a first wall that is parallel to the first planar surface and an opposing second wall that is angled relative to the second planar surface.

FIELD

The present invention relates to millwork for commercial and residential applications. More specifically, the present invention relates to a wall panel for covering vertical surfaces having with asymmetrically rabbeted longitudinal edges, such that these longitudinal edges can engage with one another when installed on an underlying support surface.

BACKGROUND

Wall paneling systems have been developed to cover the vertical surfaces of both interior and exterior walls. For example, vinyl siding, cedar shakes and cement boards are all well-known materials for covering the exterior surfaces of a building while wooden panelling and gypsum boards are often used to finish the interior vertical surfaces of a building. Suitable wall paneling systems must be attractive yet sufficiently durable for a variety of applications.

As will be readily appreciated, it is preferable if wall panelling components are easy to clean and easy to install on a variety of underlying support surfaces. Moreover, it is preferable if a wall panelling system can be securely mounted to a vertical surface without the appearance of unsightly mechanical hardware.

Moreover, it is also preferable if a wall panelling system can be manufactured out of affordable and durable materials such as fibreboard or plastic composites and also out of more luxurious materials such as hardwoods depending on the aesthetic needs of the particular end user application.

Accordingly there is a need for a wall paneling system that is easy to clean and install, durable, aesthetically appealing and economical to manufacture from a variety of materials.

BRIEF SUMMARY

It is contemplated that the present invention can provide a wall panelling system that is easy to clean and install, durable, aesthetically appealing and economical to manufacture from a variety of materials.

In at least one embodiment the present invention can provide wall panel longitudinally extending between a first end and a second end and having a first inner surface, a second outer surface, a first longitudinal edge and a second longitudinal edge, the first longitudinal edge having a first longitudinally extending rabbet that abuts the first planar surface and having a longitudinally extending perpendicular shoulder wall adjoining a longitudinally extending outer planar surface parallel to the first planar surface, a second longitudinally extending rabbit that abuts the second planar surface and having a longitudinally extending perpendicular second shoulder wall adjoining a longitudinally extending sloped portion, the first longitudinally extending rabbet being wider than the second longitudinally extending rabbet, the second longitudinal edge having a longitudinally extending first flange abutting the first planar surface and having a first flange edge, a longitudinally extending second flange abutting the second planar surface and having a second flange edge, the first flange being wider than the second flange, the first flange and the second flange defining a longitudinally extending groove therebetween, the groove having a first wall that is parallel to the first planar surface and an opposing second wall that is angled relative to the second planar surface.

DESCRIPTION OF THE DRAWINGS

The present invention will be better understood in connection with the following Figures, in which:

FIG. 1 is a cross-sectional view of a wall panel in accordance with at least one embodiment of the present invention;

FIG. 2 is a cross-sectional view of the joint between adjacent, installed wall panels in accordance with at least one embodiment of the present invention; and

FIGS. 3A to 3C are perspective views of multiple installed wall panels in a variety of configurations in accordance with several specific embodiments of the present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

It is contemplated that the present invention can provide a wall panelling system that is easy to clean and install, durable, aesthetically appealing and economical to manufacture from a variety of materials.

As will be appreciated by the skilled person, the present wall panel can be formed out of any suitable material as required by the specific end user application of the present invention including but not limited to fibreboard, plywood, hardwood, softwood, carbon fibre, various metals and composite plastics among other suitable materials having the suitable physical properties and aesthetic qualities required by the particular end user application.

Moreover, it is contemplated that the present invention can be formed of by any suitable manufacturing process and of any suitable dimensions as required by the needs of the particular end user application. For example it is contemplated that the present invention can be arranged as a thin, rectangular wall panel or a wide rectangular wall panel depending on the needs of the particular end-user application selected.

Moreover, it is contemplated that the present invention can be installed in vertical arrays or horizontal arrays on a vertical surface, and moreover in some embodiments can be installed on a ceiling or as flooring if suitable materials are selected, as will be readily appreciated by the skilled person.

As will be appreciated by the skilled person, it is contemplated that all adjoining surfaces of the present invention can be finished with a perfect 90 degree corner or with any number of radiuses, chamfers or fillets as will be appreciated by the skilled person.

Turning to FIG. 1, at least one embodiment of a cross section of a wall panel in accordance with the present invention is illustrated. In this embodiment wall panel 10 has a first inner surface 12, a second outer surface 14, a first longitudinal edge 16 and a second longitudinal edge 18. It is contemplated that wall panel 10 extends longitudinally between a first end and a second end.

In this embodiment, first longitudinal edge 16 has a first longitudinally extending rabbet 20 that abuts second outer surface 14. In this embodiment first longitudinally extending rabbet 20 has a longitudinally extending perpendicular shoulder wall 22 that adjoins both second outer surface 14 and a longitudinally extending outer planar surface 24 that is parallelly oriented relative to first inner surface 12 and second outer surface 14.

In this embodiment, outer planar surface 24 has a longitudinally extending recessed groove 26 for receiving a mechanical fastener, such as but not limited to a nail, screw, bolt or rivet. In this way, it is contemplated that a mechanical fastener can sit within the recessed groove 26 such that a second, adjacent wall panel can be mounted flushly against outer planar surface 24 of a first, installed wall panel, as will be discussed in further detail below in connection with FIGS. 2 and 3A to 3C. Moreover, it is contemplated that recessed groove 26 can be a continuous groove or a plurality of separate, discontinuous grooves as required by the needs of the particular end-user application selected.

In this embodiment, first longitudinal edge 16 also has a second longitudinally extending rabbet 30 that abuts the first inner surface 12. In this embodiment second longitudinally extending rabbet 30 has a longitudinally extending perpendicular shoulder wall 32 that adjoins both first inner surface 12 and a longitudinally extending outer sloped portion 34 that is angled in orientation relative to first inner surface 12 and second outer surface 14.

In this embodiment, second longitudinal edge 18 has a longitudinally extending first flange 40 that abuts first inner surface 12 and has a first flange edge 42 and a longitudinally extending second flange 44 that abuts second outer surface 14 and has a second flange edge 46. In this embodiment, it is contemplated that second flange 44 is wider than the first flange 40.

Moreover, in this embodiment it is contemplated that first flange 40 and second flange 44 defines a longitudinally extending groove 48 therebetween. In this embodiment it is contemplated that groove 48 has a first wall 50 that is parallel to first inner surface 12 and second outer surface 14 and an opposing second wall 52 that is angled relative to first inner surface 12 and second outer surface 14.

In this way and as can be seen in FIG. 2, first longitudinal edge 16 of a first wall panel can fit within groove 48 defined by first flange 40 and second flange 44 of second longitudinal edge 18 of an adjacent, second wall panel. As will be appreciated by the skilled person, mechanical fasteners can be inserted into recessed groove 26, thereby fixing a first wall panel in place.

Next and given the geometry of outer sloped portion 34 of a first wall panel and opposing second wall 52 of a second wall panel and given that the second flange 44 of the second wall panel is wider than the opposing first flange 40 of the second wall panel, the second wall panel can be slipped into place such that groove 48 of the second wall panel can receive first longitudinal edge 16 of a fixed first wall panel, thereby covering up recessed groove 26 from view when the two panels are installed.

In this way a wall panel can be secured to an underlying vertical surface adjacent first longitudinal edge 16 by a mechanical fastener positioned within the recessed groove 26 and along second longitudinal edge 18 by the locking interaction between the groove 48 and the first longitudinal edge 16 of a fixed adjacent panel, as will be readily appreciated by the skilled person.

Turning to FIGS. 3A to 3C, a number of different installation configurations are illustrated for a wall panel in accordance with the present invention. With reference to FIG. 3A, several wall panels 10 can be mounted in a horizontal army on a vertical surface that is comprised, in this embodiment, of multiple vertical wall studs 60, although other arrangements are also contemplated as will be discussed in further detail below. In this embodiment it is contemplated that a mechanical fastener 52 can be inserted into a groove provided in the outer planar surface of the wall panel 10, such that wall panel can be mounted directly to studs 60 by way of mechanical fastener 52.

In this way, wall panel 10 can be secured to the underlying vertical surface adjacent second longitudinal edge 18 by a mechanical fastener 52 positioned within the recessed groove and along the first longitudinal edge 16 by the locking interaction between the groove (provided on second longitudinal edge 18 as discussed above) and first longitudinal edge 16 of a fixed adjacent wall panel 10, as will be readily appreciated by the skilled person.

With reference to FIG. 3B, several wall panels 10 can be mounted in a horizontal array on a vertical surface that is comprised, in this embodiment, of multiple vertical wall studs 60 supporting an underlying wall surface 62, although other arrangements are also contemplated as will be discussed in further detail herein. In this embodiment it is contemplated that a mechanical fastener 52 can be inserted into a groove provided in the outer planar surface of the wall panel 10, such that wall panel can be mounted directly to wall surface 62 by way of mechanical fastener 52.

In this way, wall panel 10 can be secured to the underlying vertical surface adjacent second longitudinal edge 18 by a mechanical fastener 52 positioned within the recessed groove and along the first longitudinal edge 16 by the locking interaction between the groove (provided on second longitudinal edge 18 as discussed above) and first longitudinal edge 16 of a fixed adjacent wall panel 10, as will be readily appreciated by the skilled person.

With reference to FIG. 3C, several wall panels 10 can be mounted in a vertical array on a vertical surface that is comprised, in this embodiment, of multiple vertical wall studs 60 supporting an underlying wall surface 62 which in turn has additional horizontal strapping members 64, although other arrangements are also contemplated as discussed in further detail above. In this embodiment it is contemplated that a mechanical fastener 52 can be inserted into a groove provided in the outer planar surface of the wall panel 10, such that wall panel can be mounted directly to horizontal strapping members 64 by way of mechanical fastener 52.

In this way, wall panel 10 can be secured to the underlying vertical surface adjacent second longitudinal edge 18 by a mechanical fastener 52 positioned within the recessed groove and along the first longitudinal edge 16 by the locking interaction between the groove (provided on second longitudinal edge 18 as discussed above) and first longitudinal edge 16 of a fixed adjacent wall panel 10, as will be readily appreciated by the skilled person.

While the present invention has been described with reference to the aforementioned embodiments it will be apparent to anyone skilled in the art that there are many permutations and combinations of combining the primary response variables to achieve particular benefits. All such permutations and combinations are considered to be within the sphere and scope of this invention as defined in the claims appended hereto. 

1. A wall panel longitudinally extending between a first end and a second end and having a first inner surface, a second outer surface, a first longitudinal edge and a second longitudinal edge, the first longitudinal edge having a first longitudinally extending rabbet that abuts the second outer surface and having a longitudinally extending perpendicular shoulder wall adjoining a longitudinally extending outer planar surface parallel to the second outer surface, the outer planar surface having a longitudinally extending recessed groove adapted to receive a mechanical fastener, and having a second longitudinally extending rabbet that abuts the first inner surface and having a longitudinally extending perpendicular second shoulder wall adjoining a longitudinally extending sloped portion, the first longitudinally extending rabbet being wider than the second longitudinally extending rabbet, the second longitudinal edge having a longitudinally extending first flange abutting the first inner surface and having a first flange edge, a longitudinally extending second flange abutting the second outer surface and having a second flange edge, the second flange being wider than the first flange, the first flange and the second flange defining a longitudinally extending groove therebetween, the groove having a first wall that is parallel to the first inner surface and an opposing second wall that is angled relative to the second outer surface.
 2. (canceled)
 3. The wall panel of claim 1 wherein at least one of the first longitudinal edge, the first flange edge and the second flange edge have a rounded profile. 